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US20140208684A1 - Jointing and surface compound for construction elements, its preparation process and building process of a structure - Google Patents

Jointing and surface compound for construction elements, its preparation process and building process of a structure Download PDF

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Publication number
US20140208684A1
US20140208684A1 US14/243,546 US201414243546A US2014208684A1 US 20140208684 A1 US20140208684 A1 US 20140208684A1 US 201414243546 A US201414243546 A US 201414243546A US 2014208684 A1 US2014208684 A1 US 2014208684A1
Authority
US
United States
Prior art keywords
compound
drying
process according
filling
gypsum
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US14/243,546
Inventor
Alain Petit
Marc Domenech
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Certainteed Gypsum Operating Co LLC
Original Assignee
Continental Building Products Operating Co LLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Continental Building Products Operating Co LLC filed Critical Continental Building Products Operating Co LLC
Priority to US14/243,546 priority Critical patent/US20140208684A1/en
Publication of US20140208684A1 publication Critical patent/US20140208684A1/en
Abandoned legal-status Critical Current

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B14/02—Granular materials, e.g. microballoons
    • C04B14/26—Carbonates
    • C04B14/28—Carbonates of calcium
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/66—Sealings
    • E04B1/68—Sealings of joints, e.g. expansion joints
    • E04B1/6801—Fillings therefor
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B14/02—Granular materials, e.g. microballoons
    • C04B14/04—Silica-rich materials; Silicates
    • C04B14/10—Clay
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B14/02—Granular materials, e.g. microballoons
    • C04B14/04—Silica-rich materials; Silicates
    • C04B14/20—Mica; Vermiculite
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
    • C04B26/02—Macromolecular compounds
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/14—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements
    • C04B28/142—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements containing synthetic or waste calcium sulfate cements
    • C04B28/144—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements containing synthetic or waste calcium sulfate cements the synthetic calcium sulfate being a flue gas desulfurization product
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/02—Coverings or linings, e.g. for walls or ceilings of plastic materials hardening after applying, e.g. plaster
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/14—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements stone or stone-like materials, e.g. ceramics concrete; of glass or with an outer layer of stone or stone-like materials or glass
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F21/00—Implements for finishing work on buildings
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00482—Coating or impregnation materials
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00663—Uses not provided for elsewhere in C04B2111/00 as filling material for cavities or the like
    • C04B2111/00672—Pointing or jointing materials
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/91—Use of waste materials as fillers for mortars or concrete

Definitions

  • the present invention provides a jointing compound for construction elements, particularly gypsum boards with paper facings, as well as a building process of a structure such as a partition wall, a wall lining or a ceiling.
  • the invention relates to a drying compound called “ready-mix”.
  • the compound according to the invention is preferably a “2-in-1” compound, that is a compound that fulfills both the filling and the finishing functions.
  • gypsum boards are well known to make partition walls, to line vertical or inclined elements or to put up ceilings, suspended or not.
  • These boards generally comprise a core mostly made of gypsum, covered on each of its sides by a sheet serving both as reinforcement and as facing and that can comprise cardboard or mineral fibers.
  • the gypsum boards are assembled with a first compound and the joints are finished between the boards with a complementary compound.
  • a filling compound (or also called a patching compound) is used as a complement to the tape, and generally presents a relatively low shrinkage, good embedding and good adherence to the joint tape.
  • a finishing compound is used for the last pass to finish the structure so that it presents a monolithic surface.
  • drying compounds that fulfill the various functions at the same time. These compounds are called “2-in-1”, that is a compound that fulfils both the filling and the finishing functions. Moreover, drying compounds supplied in cans with. water that is later eliminated are also used; such compounds are qualified as “ready-mix”.
  • the invention therefore provides a drying compound comprising from 50 to 85% of FGD gypsum.
  • the invention therefore also provides a drying compound comprising from 50 to 85% of natural gypsum or processed gypsum, in mass percentages relative to the total mass of the compound, presenting the following particle size characteristics: (i) a d 50 from 35 to 70 ⁇ m (preferably from 36 to 70 ⁇ m, more preferably from 37 to 70 ⁇ m) and (ii) a span (d 90 -d 10 /d 50 ) lower than 2.
  • the invention also provides a preparation process for the compound according to the invention wherein the components of the compound are mixed in any order.
  • the invention provides a building process of a structure, including the juxtaposition of gypsum boards presenting a facer, preferably paper, possibly applying tape, and covering the joint between the boards using a compound according to the invention.
  • the invention provides a compound that presents good workability.
  • the workability can be divided in two parts, the first part being related to the flowing threshold of the compound, that is, the energy necessary to apply the compound, and the second being the spread after the flowing threshold. Good spreads are particularly sought after.
  • the compound according to the invention comprises, as previously mentioned, a mineral filler that is the main characteristic of this compound.
  • This mineral filler is an FGD gypsum, (Flue Gas Desulfuration) and/or a natural or processed gypsum having the following characteristics: (i) a d 50 of from to 70 ⁇ m and (ii) a span (d 90 l -d 10 /d 50 ) lower than 2.
  • the value of the span characterizes a very narrow particle size distribution.
  • a typically-used limestone as a filler in compounds presents (i) a d 50 of from 15 to 30 ⁇ m and (ii) a span (d 90 -d 10 /d 50 ) of from 2 to 4.
  • the particle size distribution can be obtained by an appropriate treatment of a natural or processed gypsum by grinding and sieving. Such techniques are known. Alternately, an FGD gypsum can be used such as directly obtained at the outlet of a desulfuration unit, these gypsums generally present the required particle size distributions.
  • d 50 is recalled, abbreviated to d(v,50), that is the size of the particle for which 50% of the sample has a smaller size and 50% of the sample has a larger size.
  • This value is also known by the name of MMD (Mass Median Diameter), the values of mass and volume being the same, simply derived one from the other by the density.
  • d 10 is the size of the particle for which 10% of the sample is below this size.
  • d 90 is the size of the particle for which 90% of the sample is below this size.
  • the amount of gypsum filler according to the invention is typically of from 50 to 85% of the total weight of the compound, preferably from 55 to 75%.
  • the mineral filler is the main characteristic of the compound according to the invention.
  • the other components are typical in the domain of drying compounds; the remainder includes water and possibly other components.
  • a complementary mineral filler can also be used, that can be any mineral filler usually-used to manufacture a jointing compound.
  • Complementary mineral fillers include calcium carbonate, calcium sulfate, anhydrous or dehydrate, magnesium carbonate, dolomite, silicas, silicates, aluminates or others.
  • a light filler (called “light weight aggregate”) can also be used if desired.
  • An example is perlite, notably expanded and in particular hydrophobe (notably with a d50 of from 20 to 100 microns).
  • the binder used is a typical binder used in the art of compounds, dispersible in the aqueous phase. It can come in the form of a dry extract or in the form, for example of latex, at 50% in water.
  • binders include polyvinyl alcohol homopolymers, polyvinyl acetate homopolymers (plasticized or non plasticized), the copolymers: ethylene/vinyl acetate (EVA) plasticized or non plasticized, ethylene/vinyl versatate, vinyl acetate/vinyl versatate, polyacrylics, the copolymers: vinyl acetate/acrylic, the copolymers: styrenic/acrylic, styrene/butadiene, terpolymers: vinyl acetate/vinyl versatate/vinyl maleate, vinyl acetate/vinyl versatate/acrylics, the terpolymer vinyl acetate/ester vinyl of an acid (long chain)/ester of acrylic acid,
  • binders could be used in this way: co- or terpolymer vinyl acetate/vinylic copolymer and vinylic copolymer/styrenic/acrylic copolymer.
  • these polymers are either in the form of powder, or in the form of dispersion in water (generally at an approximate level of 50%).
  • the proportion of organic binder is generally of from 0.5 to 20% in weight, preferably from 1 to 8% of the total weight of the compound.
  • the compound generally comprises one or several of the following other elements:
  • the compound according to the invention presents a density generally of from 1 to 1.8, preferably from 1.1 to 1.5.
  • the compound generally presents a Brookfield viscosity of the compound of from 200 000 to 800 000 cps, advantageously from 300 000 to 600 000 cps. Generally the variation between measurements after 1 day and after 7 days is relatively low (7 day/1 day ratio lower than 1.3).
  • the compound according to the invention presents a pH, for example of from 8 to 9.5.
  • the compound according to the invention presents a dry extract that can vary, for example from 60 to 85%, preferably from 70 to 80%.
  • the compound according to the invention is a compound called drying (“ready-mix”).
  • the compound according to the invention is preferably a “2-in-1” compound, that is a compound that fulfills the filling and the finishing functions at the same time.
  • the compound according to the invention presents, besides its very good easiness-to-handle (workability), one or several of the following properties:
  • the compound according to the invention can be prepared by mixing its components in any order or in a given-order.
  • the compound according to the invention can be used to make, using gypsum boards, many structures such as partition walls, wall linings and ceilings, suspended or not.
  • the compound according to the invention is particularly suitable to build structures using gypsum boards with paper facers.
  • the construction of a structure using gypsum boards generally includes the juxtaposition of gypsum boards, filling the space between the boards with a filling compound, applying tape (usually paper), covering the tape with the filling compound, then applying over the filling compound a finishing compound.
  • tape usually paper
  • the filling of the space between the boards using a filling compound and tape application steps can be replaced by applying self-adhesive glass mesh tape (without the prior application of the filling compound).
  • the compound according to the invention can be the filling compound and/or the finishing compound.
  • the compound according to the invention is both the filling compound and the finishing compound (it works then as a 2-in-1 compound).
  • paper tape or another usually-used means can generally be used, with a prior layer of the filling compound.
  • the compound is used in the same way.
  • the particle size data are given in volume (this is equivalent to data in mass), and were measured with a Malvern® mastersizer S apparatus, optic 300RF and device MS17, length of ray 2.4 mm.
  • the particle size measurement was carried out by the humid method and ultrasounds. This method consisted of diluting the filler in a solvent (95% ethanol) and applying ultrasounds (a few minutes until the sample was acceptable, value “/div” lower than 20, preferably lower than 10). The sample was introduced up to an “obscuration” value of approximately 15%.
  • the viscosity was measured by a Brookfield viscometer (RVDVII+Pro) with a Helipath device (conditioned laboratory: speed conditions No. 2, T pin No. D, measurements after 30 sec).
  • composition was determined for the characteristics given in the chart below (the FGD gypsum was the gypsum from Germany):
  • the compound was made by mixing its components.
  • the viscosity after one day was 410 000-430 000 cps, while the viscosity after 7 days was 470 000-480 000 cps. Density was from 1.23 to 1.25, and the pH was from 8.8 to 8.73.
  • Composition A Composition B Aspect pleasant shiny paste pleasant shiny paste, slight foam Odor None None Color Light brown Light brown Consistency Very good Slightly thicker than the other compound Application Excellent Excellent, with slightly more energy for the application Water retention Excellent Excellent Excellent Paper tape Very easy Very easy (Fiber)glass Excellent Excellent mesh tape Filling Excellent Excellent Shrinkage Low Low Finish Perfect Perfect Dried aspect
  • the compound behaves The compound behaves like a self-leveling like a self-leveling one and its aspect is one and its aspect is excellent excellent Sanding Easy, rapid and good Easy, rapid and good P 80 + P 150 result result result result Adhesion to the Delamination Delamination paper tape

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Architecture (AREA)
  • Structural Engineering (AREA)
  • Civil Engineering (AREA)
  • Organic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Electromagnetism (AREA)
  • Physics & Mathematics (AREA)
  • Dispersion Chemistry (AREA)
  • Paints Or Removers (AREA)
  • Finishing Walls (AREA)
  • Adhesives Or Adhesive Processes (AREA)
  • Building Environments (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)

Abstract

The object of the invention is a drying compound comprising from 50 to 85% of FGD gypsum and/or natural or processed gypsum, in mass percentages based on the total mass of the compound, presenting the following particle size characteristics: (i) a d50 from 35 to 70 μm and (ii) a span (d90-d10/d50) lower than 2. The object of the invention is also a preparation process of the compound according to the invention. Finally, the object of the invention is a building process of a structure using this compound.

Description

    CROSS-REFERENCE TO RELATED APPLICATIONS
  • This application is a continuation of application Ser. No. 13/328,840, filed on Dec. 16, 2011, which in turn is a divisional of application Ser. No. 12/065,676, filed Mar. 4, 2008, which was the National Stage filing under §371 of PCT/FR2006/002084, filed Sep. 12, 2006, which in turn claims priority to French Application No. 0509259, filed Sep. 12, 2005, the entire content of each of which is incorporated herein by reference.
    • DOMAIN OF THE INVENTION
  • The present invention provides a jointing compound for construction elements, particularly gypsum boards with paper facings, as well as a building process of a structure such as a partition wall, a wall lining or a ceiling. The invention relates to a drying compound called “ready-mix”. The compound according to the invention is preferably a “2-in-1” compound, that is a compound that fulfills both the filling and the finishing functions.
    • TECHNOLGICAL BACKGROUND
  • The use of gypsum boards is well known to make partition walls, to line vertical or inclined elements or to put up ceilings, suspended or not.
  • These boards generally comprise a core mostly made of gypsum, covered on each of its sides by a sheet serving both as reinforcement and as facing and that can comprise cardboard or mineral fibers.
  • Generally, the gypsum boards are assembled with a first compound and the joints are finished between the boards with a complementary compound. A filling compound (or also called a patching compound) is used as a complement to the tape, and generally presents a relatively low shrinkage, good embedding and good adherence to the joint tape. A finishing compound is used for the last pass to finish the structure so that it presents a monolithic surface.
  • More and more often drying compounds are used that fulfill the various functions at the same time. These compounds are called “2-in-1”, that is a compound that fulfils both the filling and the finishing functions. Moreover, drying compounds supplied in cans with. water that is later eliminated are also used; such compounds are qualified as “ready-mix”.
  • There always exists a need for a compound presenting good application qualities on the support and workability.
    • RESUME OF THE INVENTION
  • The invention therefore provides a drying compound comprising from 50 to 85% of FGD gypsum.
  • The invention therefore also provides a drying compound comprising from 50 to 85% of natural gypsum or processed gypsum, in mass percentages relative to the total mass of the compound, presenting the following particle size characteristics: (i) a d50 from 35 to 70 μm (preferably from 36 to 70 μm, more preferably from 37 to 70 μm) and (ii) a span (d90-d10/d50) lower than 2.
  • The invention also provides a preparation process for the compound according to the invention wherein the components of the compound are mixed in any order.
  • Finally, the invention provides a building process of a structure, including the juxtaposition of gypsum boards presenting a facer, preferably paper, possibly applying tape, and covering the joint between the boards using a compound according to the invention.
  • The invention provides a compound that presents good workability. The workability can be divided in two parts, the first part being related to the flowing threshold of the compound, that is, the energy necessary to apply the compound, and the second being the spread after the flowing threshold. Good spreads are particularly sought after.
    • DETAILED DESCRIPTION OF THE INVENTION Compound According to the Invention
  • The compound according to the invention comprises, as previously mentioned, a mineral filler that is the main characteristic of this compound. This mineral filler is an FGD gypsum, (Flue Gas Desulfuration) and/or a natural or processed gypsum having the following characteristics: (i) a d50 of from to 70 μm and (ii) a span (d90 l -d 10/d50) lower than 2. The value of the span characterizes a very narrow particle size distribution. As a reminder, a typically-used limestone as a filler in compounds presents (i) a d50 of from 15 to 30 μm and (ii) a span (d90-d10/d50) of from 2 to 4. The particle size distribution can be obtained by an appropriate treatment of a natural or processed gypsum by grinding and sieving. Such techniques are known. Alternately, an FGD gypsum can be used such as directly obtained at the outlet of a desulfuration unit, these gypsums generally present the required particle size distributions.
  • The definition of d50 is recalled, abbreviated to d(v,50), that is the size of the particle for which 50% of the sample has a smaller size and 50% of the sample has a larger size. This value is also known by the name of MMD (Mass Median Diameter), the values of mass and volume being the same, simply derived one from the other by the density. The value of d10 is the size of the particle for which 10% of the sample is below this size. The value of d90 is the size of the particle for which 90% of the sample is below this size.
  • The amount of gypsum filler according to the invention is typically of from 50 to 85% of the total weight of the compound, preferably from 55 to 75%.
  • The mineral filler is the main characteristic of the compound according to the invention. The other components are typical in the domain of drying compounds; the remainder includes water and possibly other components.
  • A complementary mineral filler can also be used, that can be any mineral filler usually-used to manufacture a jointing compound. Complementary mineral fillers include calcium carbonate, calcium sulfate, anhydrous or dehydrate, magnesium carbonate, dolomite, silicas, silicates, aluminates or others. Preferably the FGD gypsum and/or with a specific particle size distribution is the only one used.
  • A light filler (called “light weight aggregate”) can also be used if desired. An example is perlite, notably expanded and in particular hydrophobe (notably with a d50 of from 20 to 100 microns).
  • The binder used is a typical binder used in the art of compounds, dispersible in the aqueous phase. It can come in the form of a dry extract or in the form, for example of latex, at 50% in water. Examples of such binders, include polyvinyl alcohol homopolymers, polyvinyl acetate homopolymers (plasticized or non plasticized), the copolymers: ethylene/vinyl acetate (EVA) plasticized or non plasticized, ethylene/vinyl versatate, vinyl acetate/vinyl versatate, polyacrylics, the copolymers: vinyl acetate/acrylic, the copolymers: styrenic/acrylic, styrene/butadiene, terpolymers: vinyl acetate/vinyl versatate/vinyl maleate, vinyl acetate/vinyl versatate/acrylics, the terpolymer vinyl acetate/ester vinyl of an acid (long chain)/ester of acrylic acid, the acrylic terpolymers and mixtures thereof. Combinations of binders could be used in this way: co- or terpolymer vinyl acetate/vinylic copolymer and vinylic copolymer/styrenic/acrylic copolymer. When these polymers are provided, they are either in the form of powder, or in the form of dispersion in water (generally at an approximate level of 50%).
  • The proportion of organic binder is generally of from 0.5 to 20% in weight, preferably from 1 to 8% of the total weight of the compound.
  • Other than the elements mentioned above, the compound generally comprises one or several of the following other elements:
      • a spreading agent in amounts for example of from 0.5 to 10%, preferably from 1 to 5%; this spreading agent can be a silcated agent (different from the mineral filler) notably a clay (the attapulgite type) or it can be any known spreading agent; this agent is notably a clay and/or talc and/or mica;
      • a workability agent that is a water-retaining and thickening agent, in amounts for example from 1 to 15%; this water-retaining agent can be a cellulose derivative (cellulose ether) such as methylhydroxyethylcellulose;
      • an anti-foaming agent, in amounts for example of from 1 to 15%; this anti-foaming agent is for example a non-ionic surfactant;
      • a hydrophobe agent in amounts for example of from 1 to 15%; this agent can notably be a fatty acid, a fatty acid salt, wax or a silicone derivative; the fatty acid, oleic acid or stearic acid are preferably used, the alkaline or alkaline-earth salts are preferred for the fatty acid salt, particularly sodium, potassium, magnesium or calcium salts; the siliconates, silanes, hydrogenated silicone oils, silicone emulsions, amine-silicone emulsions, alkyl-siloxane resins such as hydrogenomethylpolysiloxane and amine polydimethylsiloxane as well as their mixes can be noted for the silicone derivatives.
      • starch and/or a starch derivative, in amounts generally of from 0.05 to 5%, preferably from 0.1 to 1% of the total weight of the compound;
      • biocides;
      • pigments and brighteners;
      • dispersing agents;
      • anti-freeze agents;
      • etc.
  • The compound according to the invention presents a density generally of from 1 to 1.8, preferably from 1.1 to 1.5.
  • The compound generally presents a Brookfield viscosity of the compound of from 200 000 to 800 000 cps, advantageously from 300 000 to 600 000 cps. Generally the variation between measurements after 1 day and after 7 days is relatively low (7 day/1 day ratio lower than 1.3).
  • The compound according to the invention presents a pH, for example of from 8 to 9.5.
  • The compound according to the invention presents a dry extract that can vary, for example from 60 to 85%, preferably from 70 to 80%.
  • The compound according to the invention is a compound called drying (“ready-mix”). The compound according to the invention is preferably a “2-in-1” compound, that is a compound that fulfills the filling and the finishing functions at the same time.
  • The compound according to the invention presents, besides its very good easiness-to-handle (workability), one or several of the following properties:
      • good adherence on the paper that is the facer of the gypsum boards (there is in fact cohesion failure in the gypsum board; there is delamination of the facing paper);
      • good embedding and good adherence of the joint tape (there is delamination of the latter);
      • low shrinkage after drying (for example less than 20% as determined by the ring test);
      • easy sanding.
  • The compound according to the invention can be prepared by mixing its components in any order or in a given-order.
  • Building Process According to the Invention
  • The compound according to the invention can be used to make, using gypsum boards, many structures such as partition walls, wall linings and ceilings, suspended or not.
  • The compound according to the invention is particularly suitable to build structures using gypsum boards with paper facers.
  • The construction of a structure using gypsum boards generally includes the juxtaposition of gypsum boards, filling the space between the boards with a filling compound, applying tape (usually paper), covering the tape with the filling compound, then applying over the filling compound a finishing compound. Alternatively, the filling of the space between the boards using a filling compound and tape application steps can be replaced by applying self-adhesive glass mesh tape (without the prior application of the filling compound).
  • The compound according to the invention can be the filling compound and/or the finishing compound. Preferably the compound according to the invention is both the filling compound and the finishing compound (it works then as a 2-in-1 compound).
  • For the joints of the recessed edges, paper tape or another usually-used means can generally be used, with a prior layer of the filling compound. For the joints on rounded edges, hence without tape, the compound is used in the same way.
    • EXAMPLES
  • The following examples are only given as an illustration and are not at all restrictive.
  • The particle size data are given in volume (this is equivalent to data in mass), and were measured with a Malvern® mastersizer S apparatus, optic 300RF and device MS17, length of ray 2.4 mm. The particle size measurement was carried out by the humid method and ultrasounds. This method consisted of diluting the filler in a solvent (95% ethanol) and applying ultrasounds (a few minutes until the sample was acceptable, value “/div” lower than 20, preferably lower than 10). The sample was introduced up to an “obscuration” value of approximately 15%.
  • The viscosity was measured by a Brookfield viscometer (RVDVII+Pro) with a Helipath device (conditioned laboratory: speed conditions No. 2, T pin No. D, measurements after 30 sec).
    • Example 1
  • In this example the characteristics of several gypsums with FGD origins were determined. The values were the following:
  • Gypsum (origin) d50 Span
    US 45.6 1.19
    Germany 65.9 1.48
    China (1) 39.9 1.87
    China (2) 44.8 1.75
    • Example 2
  • In this example the composition was determined for the characteristics given in the chart below (the FGD gypsum was the gypsum from Germany):
  • Components Quantity
    Gypsum FGD 505
    Water 200
    Microbiocide 0.48
    Nonionic surfactant 0.85
    Mica 8
    Clay 10
    Cellulose Ether 3.2
    Starch 3
    Talc 16.76
    EVA 20
  • The compound was made by mixing its components. The viscosity after one day was 410 000-430 000 cps, while the viscosity after 7 days was 470 000-480 000 cps. Density was from 1.23 to 1.25, and the pH was from 8.8 to 8.73.
    • Example 3
  • In this example, the behavior of two compounds made using FGDs with Chinese origins 1 and 2 was studied, the composition being the same as in example 2.
  • FGD China 2 FGD China 1*
    Aspect Pleasant shiny paste Pleasant shiny paste,
    slight foam
    Odor None None
    Color Light brown Brown
    Consistency Very good, relatively Slightly thicker than
    fluid the other compound
    Application Excellent Excellent
    Water retention Excellent Excellent
    Paper tape Very easy Very easy
    (Fiber)glass Excellent Excellent
    mesh tape
    Filling Excellent Excellent
    Shrinkage Low Low
    Finish Perfect Perfect
    Dried aspect The compound behaves The compound behaves
    like a self-leveling like a self-leveling
    one and its aspect is one and its aspect is
    excellent excellent
    Sanding Easy, rapid and good Easy, rapid and good
    P 80 + P 150 result result
    Adhesion to the Delamination Delamination
    paper tape
    *The compound contained 10 g of additional water.
    • Example 4
  • In this example the behavior of the compounds made using FGD from the same German origin was studied, with different sampling dates. The compositions were identical to the one in example 2, only the date of the sample of FGD gypsum changed.
  • Composition A Composition B
    Aspect Pleasant shiny paste Pleasant shiny paste,
    slight foam
    Odor None None
    Color Light brown Light brown
    Consistency Very good Slightly thicker than
    the other compound
    Application Excellent Excellent, with
    slightly more energy
    for the application
    Water retention Excellent Excellent
    Paper tape Very easy Very easy
    (Fiber)glass Excellent Excellent
    mesh tape
    Filling Excellent Excellent
    Shrinkage Low Low
    Finish Perfect Perfect
    Dried aspect The compound behaves The compound behaves
    like a self-leveling like a self-leveling
    one and its aspect is one and its aspect is
    excellent excellent
    Sanding Easy, rapid and good Easy, rapid and good
    P 80 + P 150 result result
    Adhesion to the Delamination Delamination
    paper tape

Claims (12)

What is claimed is:
1. A building process for a structure, comprising:
obtaining a composition comprising: (a) a drying compound and (b) water;
eliminating the water from the composition;
juxtaposing gypsum boards presenting a facer; and
covering a joint between the boards using the drying compound,
wherein the drying compound comprises from 50 to 85% of a Fluid Gas Desulfurization (FGD) gypsum, in mass percentages based on the total mass of the compound, having the following particle size characteristics: (i) a d50 from 36 to 70 μm and (ii) a span (d90-d10)/d50 lower than 2, and the drying compound further comprises 0.5 to 20% by weight based on the total mass of the compound, of an organic binder selected from the group consisting of polyvinylic alcohol homopolymers, polyvinyl acetate homopolymers (plasticized or non plasticized), ethylene/vinyl acetate (EVA plasticized or non plasticized) copolymers, ethylene/vinyl versatate copolymers, vinyl acetate/vinyl versatate copolymers, polyacrylics, vinyl acetate/acrylics copolymers, styrenic/acrylic copolymers, styrene/butadiene copolymers, vinyl acetate/vinyl versatate/vinyl maleate terpolymers, vinyl acetate/vinyl versatate/acrylics terpolymers, acrylic terpolymers and mixtures thereof; and
wherein the drying compound has a density of from 1 to 1.8, a Brookfield viscosity of from 200,000 to 800,000 cps, and a pH of from 8 to 9.5.
2. The process according to claim 1, comprising juxtaposing gypsum boards, filling a space between the boards using a filling compound, applying tape, covering the tape with the filling compound, then covering the filling compound with a finishing compound, wherein the filling and/or finishing compound is the drying compound.
3. The process according to claim 2, wherein the filling and the finishing compound is the drying compound.
4. The process according to claim 1, comprising juxtaposing gypsum boards, applying self-adhesive glass mesh tape, covering the tape with a filling compound, then covering the filling compound with a finishing compound, wherein the filling and/or finishing compound is the drying compound.
5. The process according to claim 1, wherein the facer is paper and the process further comprises applying tape to the gypsum boards.
6. The process according to claim 1, wherein the drying compound comprises from 50 to 75% of the FGD gypsum, in mass percentages based on the total mass of the compound.
7. The process according to claim 1, wherein the drying compound further comprises a spreading agent in an amount of from 0.5 to 10% in mass percentages based on the total mass of the compound.
8. The process according to claim 1, wherein the drying compound further comprises a spreading agent comprising a clay and/or talc and/or mica.
9. The process according to claim 1, wherein the drying compound further comprises a workability agent that is a water-retaining agent and a thickener, in an amount of from 1 to 15% in mass percentages based on the total mass of the compound.
10. The process according to claim 1, wherein the drying compound further comprises a workability agent that is a water-retaining agent and a thickener, the water-retaining agent being a cellulose derivative.
11. The process according to claim 1, wherein the drying compound comprises the organic binder in an amount from 1 to 8 weight % based on the total mass of the compound.
12. The process according to claim 1, wherein the drying compound further comprises a spreading agent in an amount of from 1 to 5% in mass percentages based on the total mass of the compound.
US14/243,546 2005-09-12 2014-04-02 Jointing and surface compound for construction elements, its preparation process and building process of a structure Abandoned US20140208684A1 (en)

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FR0509259A FR2890652B1 (en) 2005-09-12 2005-09-12 JOINT AND SURFACING COATING FOR CONSTRUCTION ELEMENTS, PREPARATION METHOD THEREFOR, AND METHOD FOR PRODUCING A WORK.
FR0509259 2005-09-12
PCT/FR2006/002084 WO2007031636A2 (en) 2005-09-12 2006-09-12 Jointing and surface coating material for building elements, method for preparing same and method for constructing a structure
US6567608A 2008-03-04 2008-03-04
US13/328,840 US20120085064A1 (en) 2005-09-12 2011-12-16 Jointing and surface compound for construction elements, its preparation process and building process of a structure
US14/243,546 US20140208684A1 (en) 2005-09-12 2014-04-02 Jointing and surface compound for construction elements, its preparation process and building process of a structure

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AU2011241030B2 (en) * 2010-04-15 2014-12-04 Henry Company Llc Mixtures and emulsions for use in providing strength to gypsum compositions
WO2012115688A1 (en) 2011-02-24 2012-08-30 Henry Company Llc Aqueous wax emulsions having reduced solids content for use in gypsum compositions and building products
KR101066298B1 (en) * 2011-05-03 2011-09-20 파슨스 브링커호프 아시아 리미티드 Inorganic non-combustible self-leveling flooring composition
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US20250197283A1 (en) * 2023-12-13 2025-06-19 United States Gypsum Company Synthetic gypsum filler based joint compound with low coefficient of friction
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WO2007031636A3 (en) 2007-06-14
PT1926693T (en) 2019-02-11
PL1926693T3 (en) 2019-05-31
WO2007031636A2 (en) 2007-03-22
FR2890652A1 (en) 2007-03-16
CA2621927C (en) 2014-04-08
CA2621927A1 (en) 2007-03-22
FR2890652B1 (en) 2007-11-09
US20080210136A1 (en) 2008-09-04
EP1926693A2 (en) 2008-06-04
ES2710112T3 (en) 2019-04-23
EP1926693B1 (en) 2018-11-14
US20120085064A1 (en) 2012-04-12

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